frenomat und frenostat Electronic Brake Units

frenomat ® und frenostat ®
Electronic Brake Units
The quick and reliable way to bring things to a standstill
– with no mechanical wear
Hilger u. Kern Industrieelektronik

Contents
NOVAMAX INDUSTRIAL INTL LLC 8200 S Quebec St Suite A-3 Englewood, CO 80112
(303) 470-7226 Fax (303) 470-5773 Toll-Free 1-800-594-3380
www.novamaxindustrial.com
Page
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
• cUL approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
• EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
• Line choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
• Certification of mechanical stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Application / Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
frenomat 2 brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
frenostat 2000 brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Technical data: frenomat 2/frenostat 2000 brake units . . . . . . . . . . . . . . . . . . . . . . . . 9
Dimensions: frenostat 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Examples of circuits: frenostat 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Accessory: line choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Commissioning: frenomat 2/frenostat 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
International sales organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3

General information
cUL approval
frenostat and frenomat brake units listed
at Underwriters Laboratories Inc.
Important for all export-oriented companies:
As of immediately, all frenostat and
frenomat brake units from Hilger u. Kern
Industrieelektronik are cUL listed. The UL
File Number is 225692 and the Control
No. is 1 Y D 1.
Listed units with UL makes it easier to
export machinery and installations to the
USA and Canada.
The UL-listed Size 2 is made of sheet
steel and the line choke is integrated in
the unit. Size 1 (36 and 60 A) is now
supplied as a new plastic version.
EU Declaration of Conformity
Hilger u. Kern Industrieelektronik here with
declares with respect to the products it
manufactures and named below
frenomat electronic brake unit,
frenostat electronic brake unit,
that the requirements relating to electromagnetic
compatibility (EMC) as laid down
in EU Directive 89/336/EEC are met.
Assessment of the product has been based
on the following standards:
• IEC 947-4-2 AC semiconductor motor
controllers and starters
• EN 50081-1 Generic Emission Standard
03.93
• EN 50082-2 Generic Immunity Standard
08.94
The corresponding measurements have
been confirmed and documented by the
German technical inspectorate TÜV-Südwest
in Mannheim.
The units named above are labeled with a
CE mark of conformity.
Line choke
The emission limits laid down in the European
standards do not exclude interference
of receivers within a radius of 10 m.
During operation, i.e. braking, frenostat
and frenomat electronic brake units remain
within the limits of European standard EN
50081-2 (mains-borne interference) with
regard to the power cables if a line choke
is installed directly on the line terminal.
This accessory is available from Hilger u.
Kern Industrieelektronik (see page 14).
The enclosures of the frenostat brake
units are made of environmentally friendly,
recyclable materials.
4
Certification of
mechanical stability
frenostat electronic brake unit No.
12524100 has been subjected to a type
test in accordance with DIN 57 Part
2/VDE 0160 Part 2, Section 4.2.
This test is valid for all frenostat brake
units that have been manufactured since
January 1, 1978.
The results of the measurements taken
have revealed that the brake unit more
than complies with the requirements laid
down in VDE 0160 Part 2, Section 4.2.
Operational reliability of the frenostat brake
unit was unaffected.

Application /
Operating principle
frenomat and frenostat electronic brake
units
• reliably and quickly brake asynchronous
motors to a standstill without
requiring any maintenance or suffering
any wear.
• are the perfect solution for shortening
long coasting times (saving time and
costs).
• are components that can be retrofitted
in control cabinets without any problem.
• are maintenance- and wear-free.
Due to systematic action taken to meet
the demands of the market, frenomat and
frenostat electronic brake units have a
wider power spectrum than units comparable
in design. In particular, the following
features designed to increase service reliability
must be highlighted:
• visual indication of the operating state
• proven snubber circuit to protect
against voltage peaks
• generous rating of the heat sinks
• high degree of service reliability – even
under rough service and ambient
conditions – thanks to protective
lacquering
• captive connecting screws
• automatic standstill monitoring.
Basic circuitry
of the main circuit
(basic layout)
▲
Braking torque curve with
asynchronous motors as
a factor of the speed
▲
▲
Operating principle
A rugged power converter, working in
conjunction with floating, digital control
electronics, generates a powerful braking
torque.
The braking effect is initiated by an
adjustable direct current that flows through
the motor winding. A stationary magnetic
field, which acts as a static field, retards
the rotational movement of the rotor. The
braking torque that results from this follows
the curve depicted against the speed.
Application example:
vibrating screen
A frenostat 2000 electronic brake unit
brings the 30-kW drive to a standstill within
just a few seconds. This prevents dangerous
sympathetic (resonant) oscillations.
Use of the frenostat 2000 made it possible
to do without elaborate and costly concrete
foundations.
5

frenomat 2
electronic brake unit
The frenomat 2 electronic brake unit
quickly and reliably brakes three-phase
AC motors with a power output of up to 3
kW. frenomat 2 brake units are compact
and suitable for snap-fitting on DIN rails.
They are only 55 mm wide!
The control and power circuits are housed
in a rigid and unbreakable plastic enclosure.
The braking current and braking time are
both infinitely variable and can be adjusted
manually.
frenomat 2 is also equipped with a standstill
monitoring unit on terminal n1 to allow it
to be used with drives whose rotating
mass is frequently changed.
Circuit diagram
Dimensions
▲ ▲
6

frenostat 2000 electronic brake unit
This type of brake unit is used to quickly
and reliably brake three-phase AC motors
within a power output range from 3 to 100
kW to a standstill.
frenostat 2000 is available in 4 different
sizes.
Braking current control
The frenostat 2000 braking units use an
integral braking current measurement
function to control the amperage and the
braking force to the specified values set.
This simplifies commissioning and dispenses
with the need for time-consuming
measurement procedures. An ammeter is
not required to set the current.
The current level is indicated by means of
a bar display.
Control /
Status indicators
All important operating statuses are indicated
by means of LEDs.
➀ “P” – Fuse monitoring
➁ “M” – Motor On
➂ “B” – Brake active
➃ “S” –
➄ “O” –
Standstill monitoring by
sensing the motor's rotational
movement
Overheating indicator flashes
frenostat 2000 electronic brake units can
be controlled both by means of contactor
equipment or a PLC.
(24-V logic)
➅ Potentiometer for time adjustment
➆ Potentiometer for braking current
adjustment
➇ Braking current display
➀ ➁ ➂ ➃ ➄ ➅ ➆ ➇
Braking current display
LED frenostat 2000 brake units are
equipped with an LED bar displa
This display indicates the instantaneous
braking current in 10% steps.
7

Overheating protection
In order to increase operational reliability,
frenostat 2000 brake units are equipped
with an integral temperature-measuring
function.
In the event of the unit overheating, due
to too frequent braking for example, braking
is executed until the motor comes to a
standstill, but the motor is prevented from
restarting. A floating relay contact (n3, n4)
remains closed. In addition, LED “O”
flashes to indicate overheating.
Once the brake unit has cooled down to
its normal operating temperature, the
relay contact (n3, n4) is opened again.
LED “O” stops flashing.
Standstill monitoring
An integrated standstill monitoring unit
alters the operating time of the brake
depending on the variable rotating mass
of the overall drive. A manual time setting
is not needed.
Activation of this monitoring unit is indicated
by LED “S”.
The control unit is connected to terminal
n1 by means of an instrument lead (0.75
mm 2 ). Measurement is triggered by the
braking contactor by means of an auxiliary
contact. If motor leads with a cross-section
>1.5 mm 2 are used, a 2-A fuse must be
fitted to protect the instrument lead.
Interlocking contact
frenostat brake units are equipped with a
floating changeover contact. NC contact
n4 – n2 opens after the motor has started
and in this way allows the motor to be
started again only after braking has been
completed.
The interlocking contact can perform the
following functions:
• protect against overheating
• interlock immediate reclosure following
the OFF command without braking (see
examples of circuits)
• indicate readiness: the motor is only
released by a PLC for reclosure once
the contact is in its normal position
• interlock a hood or cover: a protective
hood or cover can only be opened
when the drive is at rest
• report standstill
• open a mechanical holding brake.
Choice of brake unit fuses
The 2 brake unit fuses serve among other
things to protect the motor against overloading.
These fuses must be adapted to
match the rated current of the motor.
Rated fuse current = approx. 150% of rated
motor current. See basic circuit on page
13 for circuitry of fuse F4.
Choice of braking contactor
Size of braking contactor = size of motor
contactor. The contactor is energized and
de-energized without current being applied
to the main contacts.
Size of connection cables
The cross-section of the cables connected
to terminals 8, a and b is identical to that
of the motor connection cables.
The cable connected to terminal n1 is an
instrument lead (

frenomat 2/frenostat 1000/frenostat 2000 electronic brake units
Technical data
Maximum braking current:
frenomat 2
frenostat 2000 Size 1
frenostat 2000 Size 2
frenostat 2000 Size 3
frenostat 2000 Size 4
30 A
36, 60 A
100, 150, 200 A
300, 400, 500 A
750, 1000, 1500 A
Input braking voltage:
+ 10%/ - 15% at 50 to 60 Hz
230 V to 500 V
higher than 500 V on request
Max. output braking voltage:
(V) DC
Line voltage
AC
Braking current
DC
230 V 80 V
400 V 160 V
500 V 190 V
660 V 270 V
Ambient temperature:
- 25°C to + 45°C at nominal output;
and + 60°C, reduction in at temperatures
between + 45°C braking current of 1.5%
necessary per °C
Contact load:
250 V / 5 A (at terminals 3 and 4)
Braking time:
0 to 12 seconds;
when a standstill monitoring the braking
time is set automatically unit is connected
to terminal n1/T3
ON time:
20% in relation to 1 min. (12 s/min.)
Please inquire about longer ON times
External fuses:
frenomat – max. 16 A
frenostat – approx. 150%
of rated motor current
9

▲ ▲
Dimensions
frenostat 2000 Size 1
36 A and 60 A
Height x width x depth
185 x 158 x 110 mm
Drilling dimensions in mm
145 x 137 ø 5.5 mm
Weight: 1.1 kg
Line choke for assembly outside
the unit (optional)
frenostat 2000 Size 2
100 A, 150 A and 200 A
Height x width x depth
270 x 145 x 180 mm
Drilling dimensions in mm
130 x 215 ø 6.5 mm
Weight: 7.5 kg
Line choke installed in unit
frenostat 2000 Size 3
300 A, 400 A and 500 A
Height x width x depth
270 x 145 x 180 mm
Drilling dimensions in mm
130 x 215 ø 6.5 mm
Weight: 6.5 kg
Line choke separate outside the unit
▲
10

Examples of circuits: frenostat 2000 electronic brake unit
▲
Circuit diagram 1
Basic circuit
▲
Circuit diagram 2
Motor control for reversing operation
11

▲
Circuit diagram 3
Motor control for star-delta starting; braking with star connection (2 motor windings connected in series)
▲
Circuit diagram 4
Motor control for pole changing (Dahlander); braking acting on the motor winding at high speed
12

▲
Circuit diagram 5
Motor control for pole changing; braking acting on the motor winding at high speed
▲
Circuit diagram 6
2-motor control; braking with series connection for motors >2 kW
13

▲
Circuit diagram 7
2-motor control; braking with parallel connection for motors

Commissioning
frenomat 2/frenostat 2000 electronic brake units
N.B.
• Electronic printed-circuit boards are live.
• Connect heat sinks to ground.
• Avoid using a long supply lead.
• Use an ohmmeter or multimeter.
Do not use a continuity tester or test lamp.
Activating without
braking current
Test interlocking
Remove the fuse from the motor. Set potentiometer
“T” (time) to max. (turn clockwise
as far as it will go) and potentiometer “I”
(current) to min. (turn counterclockwise as
far as it will go).
Motor contactor
K 1
On
on
Off
Braking contactor
K 2
Off
K 1 cannot be energized,
off - K On 1 interlocked
Test interlock: Energize K 2 by hand Energize K 1 by hand
K 1 de-energizes
K 2 de-energizes
▲
Operating principle
Setting the braking current
Note
Throw the motor fuse and turn potentiometer
“T” (time) through a 1/4 turn. When
the motor has reached its normal operating
temperature, slowly turn potentiometer “I”
(current) clockwise during braking and
observe the current value on the LED bar
display while doing so. 10 bars = 100%
indication = rated current of the unit.
During braking, LEDs “B” (braking) and “S”
(standstill) light up. “B” indicates energizing
of the output relays on terminals 3 and 4
and “S” monitors the rotation of the motor
(On) until the standstill (Off).
With frenostat 1000 : connect a DC -
ammeter to terminal T2.
With frenomat – 2 : connect a DC ammeter
tpo terminal b.
LED “S” is off when braking is completed.
The braking time set at potentiometer “T”
(time) accumulates automatically. This can
be set manually for post-braking that can
last up to 20 seconds.
LED “O” (overheating) flashes if the heat
sinks of the brake unit have become too
hot due to too frequent braking. The motor
cannot start again as long as this LED
flashes.
frenostat 1000 and frenomat are not
equipped with overheating protection.
15

The Hilger u. Kern / Dopag Group, which employs a workforce of more than 320 and has 6 international
subsidiaries, is one of the world's largest manufacturers of metering and mixing systems, systems that
deploy all processing concepts commonly in use for polymers and single-component media such as
greases, oils and adhesives.
The Group has been developing and building machines, installations and one-off units tailored specifically
to your requirements for more than 25 years.
Comprising 4 separate divisions specializing in Drive Technology, Metering Technology, Industrial
Electronics and Spray Technology, Hilger u. Kern Industrietechnik, located in Mannheim, is one Germany's
leading manufacturers of technically sophisticated, innovative and high-quality capital goods.
Hilger u. Kern GmbH
Drive Technology
Friction-locking and
positive drive systems
Planetary gearing
Metering
Technology
Mixing and metering systems for
polymers and 1-component media
Industrial Electronics
Electronic softstarters and
brake units, microcomputers,
machine monitoring systems
Spray Technology
Spray system, material supply,
customized systems
NOVAMAX INDUSTRIAL INTL LLC - 8200 S Quebec St Suite A-3 Englewood, CO 80112
(303) 470-7226 Fax (303) 470-5773 Toll-Free 1-800-594-3380
www.novamaxindustrial.com
Hilger u. Kern Industrieelektronik
VDE 203-2/03.2-Stork © by Hilger u. Kern Industrieelektronik Subject to change without prior notice.